Disposable air freshener including gel or polymer fragrance support

ABSTRACT

Embodiments of the invention provide a fragrance distribution device comprising an electrical resistor, a plug or other power source, and a fragrance in a polymer or thermoplastic carrier. The polymer or thermoplastic carrier may include, for example, metal inclusions, which may be powdered metal. These metal inclusions are believed to enhance heat distribution throughout the carrier, thus allowing a more uniform and reliable release of fragrance.

CLAIM TO PRIORITY

This application claims priority to U.S. Provisional Patent ApplicationNo. 60/931,358, filed on May 23, 2007, and having common inventor. Thatapplication, including all figures and drawings, is incorporated byreference as if fully rewritten herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to the fields of scent and aroma management. Thismay include, for example but not be limited to increasing the amount ofdesirable volatile organic compound (for example, fragrances) in a roomor other area.

2. Background of the Art

Many devices for providing a fragrance to an area over a period of timeare known. Generally, these devices operate by allowing a fragrancecontained in the device to diffuse from the device and into theatmosphere. Diffusion of fragrance may be enhanced, for example, byheating the fragrance, by including the fragrance in a volatile carrier,or by a combination of those. Diffusion of fragrances and their generalintensity is governed by their equilibrium vapor pressure. Fragranceswith a high equilibrium vapor pressure have a high volatility andquickly evaporate.

The useful lifespan of a fragrance device is limited by the amount offragrance that is able to be distributed from the device. After thefragrance supply of the device is exhausted, either the device isreplaced in its entirety, or the fragrance is replaced. This latter maybe done, for example, by replacement of a removable cartridge in thefragrance device.

Known devices for fragrance distribution may present a number ofheretofore unresolved challenges. For example, selection of a carrierthat allows uniform distribution of the fragrance at a selected rate isdifficult. Some carriers and fragrances evaporate too quickly. Thisresults in an undesirably short lifespan for the fragrance distributionproduct and potentially an undesirably intense aroma.

Other carriers and fragrances may diffuse too slowly, or diffuse to anextent insufficient to create the desired fragrance in a room of largesize. This could result in a fragrance concentration that is too low tobe effective for an intended use.

Use of heat to aid in the distribution of carder from a fragrance hasbeen tried in the past. Unfortunately, many heat assisted fragrancedistributors share problems with their non-heated counterparts. Forexample, fragrance may diffuse too rapidly when the carrier is heated.Because the application of heat is often not uniform across the entiretyof a fragrance diffuser (for example, when the heat is applied to onlyone side or to the bottom of a container holding the fragrance andcarrier), the fragrance may not be uniformly released from the carrier.

This is particularly troublesome in applications where the carrier is asolid carrier, and where there is no opportunity for the carrier to beplaced in contact with the heating element. This can result in lowfragrance capacity (because only a small amount of carrier is provided)or in significant wasted fragrance and carrier (because more carrier isprovided than can be placed in contact with or operatively close to theheat source.

It would be desirable to have a fragrance distribution device that isable to distribute heat uniformly or near-uniformly about the entiretyof the carrier. It would further be desirable to have a fragrancedistribution device that provides a more uniform and/or morecontrollable distribution of fragrance.

BRIEF SUMMARY OF THE INVENTION

Embodiments of the invention provide a fragrance distribution devicecomprising an electrical resistor, a plug or other power source, and afragrance in a polymer or thermoplastic carrier. The polymer orthermoplastic carrier may include, for example, metal inclusions, whichmay be powdered metal. These metal inclusions are believed to enhanceheat distribution throughout the carrier, thus allowing a more uniformand reliable release of fragrance.

A further embodiment of the invention provides a fragrance retained in apolymer or thermoplastic carrier. Metal is distributed throughout thecarrier and believed to enhance heat distribution when the carrier issubjected to heat.

Methods of providing a fragrance by using one or more of the abovestructures are also included herein.

Other aspects, objectives and advantages of the invention will becomemore apparent from the following detailed description when taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of thespecification illustrate several aspects of the present invention and,together with the description, serve to explain the principles of theinvention. In the drawings:

FIG. 1 shows multiple views of a solid reservoir (interchangeably calleda fragrance support herein) of one embodiment of the invention.

FIG. 2 shows a solid reservoir of the invention contained within afragrance distribution device of the invention. The cover may be held inplace, for example, by a snap fit or other adhesive.

FIG. 3 shows a front view of a fragrance distribution device of anembodiment of the invention.

FIG. 4 shows a resistor with plug. The resistor is covered by plastic,which may have holes in the plastic to allow heat transfer.

FIG. 5 shows an additional embodiment of the invention. It includes anoptionally screened design on the cap.

FIG. 6 shows a further embodiment of the invention.

While the invention will be described in connection with certainpreferred embodiments, there is no intent to limit it to thoseembodiments. On the contrary, the intent is to cover all alternatives,modifications and equivalents as included within the spirit and scope ofthe invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the invention provide a gel or polymer fragrance carrierincluding a fragrance and one or more other additives. In particularlypreferred embodiments of the invention, another additive is metalinclusions, preferably powdered aluminum.

Multiple views of a fragrance reservoir useful in one embodiment of theinvention are shown in FIG. 1. Such a fragrance reservoir may beenclosed within a fragrance dispensing device and/or may be moldeddirectly to a resistor. The embodiment in FIG. 2 shows a cover 1 and aplug/resistor 3, which is optionally coated in plastic. FIG. 3 shows afurther embodiment of the invention. Optional vents 7 and are alsoincluded in this embodiment. FIG. 4 shows a resistor with a conventionalplug for electricity. The fragrance reservoir may be designed to fitsnugly over the resistor. Such a design is shown in FIG. 1.

FIG. 5 shows an additional embodiment of the invention, including anoptional “child-safe” feature. In this embodiment of the invention, toprelease button 11 and side release buttons 13 and 15 must be depressedto remove the air freshener from a standard wall outlet after the safetytab 17 has engaged. FIG. 5 also shows the fragranced polymer 1, heatsink/plug combination 3 and cover 5 shown in FIG. 1. Although buttons 13and 15 server as a release mechanism in this embodiment, in anotherembodiment they may be immobile and serve as grips for easy removal ofthe air freshener from an outlet.

FIG. 6 shows an embodiment of the invention including a disposable,replaceable fragranced polymer 19 that is placed in a resistor/plug tray21. This tray is then inserted in a housing 23 that may optionallyinclude safety releases 11, 13, and 15. The embodiment shown in FIG. 14also includes a cutout 25 with a screen 27 allowing release of thefragrance.

Polymer Carriers

Embodiments of the invention include the fragrances in a polymericcarrier, which also may be referred to herein as a reservoir. Onepreferred polymeric carrier is polyethylene vinyl acetate (EVA). EVA isa copolymer of ethylene and vinyl acetate. The EVA has no odor by itsnature, however, it can adsorb or otherwise be permeated with afragrance. EVA approaches elastomeric materials in softness andflexibility, yet can be processed like thermoplastics. EVA is alsomoderately effective in the distribution of heat necessary to provide anapproximately uniform heating effect throughout the polymeric carrier.

EVA used in the invention may have a molecular weight in the range of,for example, 10,000 Daltons to 100,000 Daltons, more preferably 22,000to 87,000 Daltons. Fragrance may be introduced into the polymer atweight percents varying from 10 to 90%, from 20 to 80% from 30 to 70%,from 30 to 60%, and from 30 to 50%. In further embodiments, fragrance isintroduced into the polymer at a weight percent of about 1%, about 10%,about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about80%, about 90%, or about 95%.

Other elastomeric or thermoplastic carriers or combinations thereof maybe used as carriers, so long as they will release fragrance uponheating. Other suitable polymeric materials share the beneficialproperties of EVA and may be substituted for use in embodiments of theinvention. These include, for example, but are not limited to ethylvinyl alcohol, high density polyethylene, low density polyethylene,polystyrene, acrylic polymers, polycarbonates, polyurethanes, nylons,and mixtures and copolymers of the foregoing.

Gellants may also be used as a fragrance support. For example, an IFOgel (for example, a polyamide gel) is one suitable example of a gellantthat may be used in embodiments of the invention to replace all or partof the polymer component.

A preferred shape of the reservoir is shown in the figures. This maygenerally be described as half of a ribbed disk. This shape permits airflow while still allowing the maximum heat distribution and optimalfragrance release.

Fragrances

One or more fragrances or odor neutralizers may be used in embodimentsof the invention. If addition of fragrance is desired, suitablefragrances may be selected from those compiled by the U.S. Food and DrugAdministration in Title 21 of the Code of Federal Regulations, Sections172.510 and 172.515, incorporated by reference herein. Fragrancecomponents selected from benzaldehydes, phenols, cinnamic aldehydes andesters, octadienes, dienes, cyclohexadienes, and terpenes may be used inthe invention. Fragrance oils are also suitable for use alone or incombination with other fragrance chemicals. Suitable fragrance oils are,for example spice oil, flower oil, and fruit oil.

Other suitable fragrances include but are not limited to benzyl alcohol,ethyl maltol, furaneol, 1-hexanol, cis-3-hexen-1-ol, menthol,benzaldehyde, hexanal, cinnamaldehyde, citral, cis-3-hexenal, furfural,neral, vanillin, ethyl acetate, ethyl butanoate, ethyl decanoate, ethylhexanoate, ethyl octanoate, hexyl acetate, isoamyl acetate, methylbutanoate, methyl salicylate, pentyl butanoate, pentyl pentanoate,sotolon, strawberry aldehyde, fructone, anethole, anisole, eugenol,dihydrojasmone, 2-acetyl-1-pyrroline,6-acetyl-2,3,4,5-tetrahydropyridine, gamma-decalactone,gamma-nonalactone, delta-octalactone, jasmine lactone, massoia lactone,camphor, citronellol, linalool, nerol, nerolidol,alpha-terpineol,thujone, and thymol.

In further embodiments of the invention, fragrances and/or odorneutralizers are mixed with one or more hindered amines. The hinderedamines useful in the instant invention are well known in the art and aredescribed in detail in U.S. Pat. No. 6,221,115, the relevant parts ofwhich are incorporated herein by reference. Examples of the hinderedamines are:1-(2-hydroxy-2-methylpropoxy)-4-octadecanoyloxy-2,2,6,6-tetramethylpiperidine;1-(2-hydroxy-2-methylpropoxy)-4-hydroxy-2,2,6,6-tetramethylpiperidin-e;bis(1-octyloxy-2,2,6,6-tetramethylpiperidin-4-yl) sebacate;bis(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl) sebacate;1-cyclohexyloxy-2,2,6,6-tetramethyl-4-octadecylaminopiperidine;2,4-bis[(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl)butylamino]-6-(2-hydroxyethylamino-s-triazine;bis(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl) adipate;1-(2-hydroxy-2-methylpropoxy)-4-oxo-2,2,6,6-tetramethylpiperidine;bis(1-(2-hydroxy-2-methylpropoxy)-2,2,6,6-tetramethylpiperidin-4-yl)sebacate;bis(1-(2-hydroxy-2-methylpropoxy)-2,2,6,6-tetramethylpiperidin-4-yl)adipate;bis(1-(2-hydroxy-2-methylpropoxy)-2,2,6,6-tetramethylpiperidin-4-yl)succinate;bis(1-(2-hydroxy-2methylpropoxy)-2,2,6,6-tetramethylpiperidin-4-yl)glutarate; and 2,4-bis{N-[1-(2-hydroxy-2-methylpropoxy)-2,2,6,6-tetramethylpiperidin-4-y-1]-N-butylamino}-6-(2-hydroxyethylamino)-s-triazine)1-methoxy-4-hydroxy-2,2,6,6-tetramethylpiperidine;1-methoxy-4-hydroxy-2,2,6,6-tetramethylpiperidine;1-octyloxy-4-hydroxy-2,2,6,6-tetramethylpiperidine;1-cyclohexyloxy-4-hydroxy-2,2,6,6-tetramethylpiperidine;1-methoxy-4-oxo-2,2,6,6-tetramethylpiperidine;1-octyloxy-4-oxo-2,2,6,6-tetramethylpiperidine; and1-cyclohexyloxy-4-oxo-2,2,6,6-tetramethylpiperidine, or a mixturethereof.

In yet further embodiments of the invention, fragrances and/or odorneutralizers include one or more antioxidants. Antioxidants used inembodiments of the invention may be, for example, tertiarybutylhydroquinone, n-octadecyl3,5-di-tert-butyl-4-hydroxyhydrocinnamate, butylated hydroxyanisole,phenol bisphosphite, butylated hydroxytoluene, and phosphite compounds.An effective amount of antioxidant in the instant composition is 0.015%to 2.5% by weight of the EVA or other polymer, preferably 0.1 to 0.75%by weight and most preferably 0.2 to 0.5% by weight. In preferredembodiments of the invention, high concentrations of antioxidants aremixed with fragrance priori to addition of the fragrance/antioxidantmixture to any other components of the mixture.

Still further embodiments of the invention contemplate inclusion of thefragrance and/or odor neutralizer in a diluent prior to incorporationinto a polymeric carrier. A diluent is organic, for example: triethylcitrate; di-isopropropyl adipate; di-octyl adipate; isopropyl myristate;isopropyl palmitate; butyl stearate; benzyl alcohol; benzyl benzoate;and diethyl pthalate. The quantity of diluent preferred is the quantitynecessary for dissolving the fragrance or the antioxidant.

In one preferred embodiment, a selected fragrance and/or an odorneutralizer (with or without the other additives reported above) isembedded in and/or adsorbed on the polymer. Further informationregarding creation of a fragrance/antioxidant/diluent mixture may befound in U.S. Pat. No. 7,220,288, which is incorporated by reference asif fully rewritten herein.

Dispensers

In a preferred embodiment, the invention includes an economical electricdispenser for controlling the release of volatile materials within acontained environment, The dispenser may be, for example, a two-piecedisposable unit or a three-piece refillable unit as shown in theattached Figures.

The polymer fragrance reservoir is either molded on the heating elementor is molded as a snap-on piece. Such construction encourages childsafety. During operation of the air freshener, current flows through aresistor, causing the creation of heat that raises the temperature ofthe polymer and releases fragrance from the polymer.

Various resistors may be suitable for use in the invention. For example,it is expected that resistors of 5 KOhm, 8 KOhm, and 10 KOhm may beuseful in certain embodiments of the invention. The dispenser may bemodified to allow the resistor to have direct contact with or directcommunication with the polymer support, for example by adding holes tothe surface of the dispenser between the resistor and the dispenser, orby adding holes to the sides of the portion of the dispenser includingthe resistor.

Metal Inclusions

Metal inclusions may be added as a powder or as metal-coated beads ofglass or ceramic. These inclusions are thought to alleviate theinsulative properties of the fragrance support. It is believed that themetal prevents trapping of heat within the confines of the fragrancesupport.

Metal inclusion amounts may vary. For example, they may range between0.5% to 2.0%, 0.5% to 1.0%, 0.1% to 0.5% and 0.2% to 0.3% of the totalfragrance support composition by weight, including the fragrance andother additives.

Metal inclusion sizes may vary. For example, they may be powders. Onepreferred powder size is 325 mesh. Powders may range in size, forexample, between 200 mesh to 400 mesh. They may also be flakes orstrands. Metal strands may be up to 0.06 inches in length and 0.0125inches in width. Flakes may be up to 0.04 inches in diameter.

Other Additives

Various other additives such as color additives may be added indifferent embodiments depending on desired characteristics of aparticular fragrance dispenser.

Plasticizers may also be added to polymeric materials that are used inembodiments of the invention. These may include, for example, diethylphthalate and tri-acetic acid ester of glycerin.

EXAMPLES

The following examples are given to help those skilled in the artappreciate the invention. They should not be construed to limit thescope of the claims.

Example 1

Example 1 describes the construction of a polymer support containingmetal inclusions and a fragrance. An amount of fragrance that is 33.4%by weight of the anticipated final formula amount is weighed and loadedinto a vessel. Into the fragrance is added antioxidant and hinderedamine at 0.7% and 0.7% by weight of the anticipated final formulaamount, respectively. An amount of 0.2% of a color solution is added.This is mixed until dissolution.

The fragrance solution is transferred to a 5 gallon drum. EVA in theamount of 65% by weight of the anticipated final formula amount is addedas solid beads. Aluminum powder, if desired, is added at 0.3% by weightof the anticipated final formula amount. The drum is sealed and rotateduntil the fragrance mixture is completely absorbed into the EVA and thealuminum (if present) coats the beads.

The beads are loaded into an injection molding machine. It is preferredthat prior to injection molding the beads be no larger than 325 mesh. Afragrance support is created in the desired shape through the injectionmolding process. Through operation of the injection molding process, thealuminum is distributed within the structure. The finished fragrancesupport may be packaged for sale as a refill item or may be placedwithin a housing (of plastic or other material) that includes a resistorand is constructed by means known to those of skill in the packagingarts.

I claim:
 1. A fragrance distribution device, comprising: a housing, aresistor connected to said housing and capable of generating heat to betransferred to said housing a fragrance support contained within saidhousing, said fragrance support comprising a fragrance support material,at least one fragrance, and a plurality of metal inclusions distributedthroughout the fragrance support material.
 2. The fragrance distributiondevice of claim 1, wherein said fragrance support material is selectedfrom the group consisting of ethylene vinyl acetate (EVA); ethyl vinylalcohol, high density polyethylene, low density polyethylene,polystyrene, acrylic polymers, polycarbonates, polyurethanes, nylons,and mixtures and copolymers of the foregoing.
 3. The fragrancedistribution device of claim 2, wherein said fragrance support materialis EVA.
 4. The fragrance distribution device of claim 1, wherein saidmetal inclusions are selected from the group consisting of aluminum,nickel, gold, solver, copper, platinum, and mixtures thereof.
 6. Thefragrance distribution device of claim 4, wherein said metal inclusionsare aluminum.
 7. The fragrance distribution device of claim 1, whereinsaid metal inclusions are present in an amount between 0.5% to 2.0% ofthe fragrance support by weight.
 8. The fragrance distribution device ofclaim 7, wherein said metal inclusions are present in the amount of 0.1to 0.5% by weight of the fragrance support.
 9. The fragrancedistribution device of claim 1, wherein said metal inclusions arepowders that have a size ranging between 200 mesh to 400 mesh.
 10. Thefragrance distribution device of claim 9, wherein said metal inclusionsare powders that have a size of about 325 mesh.
 11. The fragrancedistribution device of claim 1, wherein said fragrance is selected fromthe group consisting of benzyl alcohol, ethyl maltol, furaneol,1-hexanol, cis-3-hexen-1-ol, menthol, benzaldehyde, hexanal,cinnamaldehyde, citral, cis-3-hexenal, furfural, neral, vanillin, ethylacetate, ethyl butanoate, ethyl decanoate, spice oil, flower oil, fruitoil, ethyl hexanoate, ethyl octanoate, hexyl acetate, isoamyl acetate,methyl butanoate, methyl salicylate, pentyl butanoate, pentylpentanoate, sotolon, strawberry aldehyde, fructone, anethole, anisole,eugenol, dihydrojasmone, 2-acetyl-1-pyrroline,6-acetyl-2,3,4,5-tetrahydropyridine, gamma-decalactone,gamma-nonalactone, delta-octalactone, jasmine lactone, massoia lactone,camphor, citronellol, linalool, nerol, nerolidol,alpha-terpineol,thujone, and thymol,
 12. The fragrance distribution device of claim 1,wherein said metal inclusions are aluminum powder having a size between200 mesh and 400 mesh and said fragrance support material is EVA.
 13. Afragrance support comprising a fragrance support material, at least onefragrance, and a plurality of metal inclusions distributed throughoutthe fragrance support material.
 14. A method of enhancing distributionof heat through a polymer fragrance support, comprising heating apolymer fragrance support to a melted state; mixing metal inclusionsinto the melted polymer fragrance support; and allowing the heatingpolymer fragrance support to cool.